101603-7770 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1016037770 1156027790

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 101603-7770 1016037770

ISUZU 1156027790 1156027790

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Cross reference number

ZEXEL 101603-7770 1016037770

ISUZU 1156027790 1156027790

Zexel num

Bosch num

Firm num

Name

101603-7770

1156027790 ISUZU

INJECTION-PUMP ASSEMBLY
6SA1 * K

Calibration Data:

Adjustment conditions

Test oil
1404 Test oil ISO4113 or {SAEJ967d}

Test oil temperature degC 40 40 45

Nozzle and nozzle holder 105780-8140

Bosch type code EF8511/9A

Nozzle 105780-0000

Bosch type code DN12SD12T

Nozzle holder 105780-2080

Bosch type code EF8511/9

Opening pressure MPa 17.2

Opening pressure kgf/cm2 175

Injection pipe
Outer diameter - inner diameter - length (mm) mm 6-2-600

Overflow valve 132424-0620

Overflow valve opening pressure kPa 157 123 191

Overflow valve opening pressure kgf/cm2 1.6 1.25 1.95

Tester oil delivery pressure kPa 157 157 157

Tester oil delivery pressure kgf/cm2 1.6 1.6 1.6

Direction of rotation (viewed from drive side)
Left L

Injection timing adjustment

Direction of rotation (viewed from drive side)
Left L

Injection order 1-5-3-6- 2-4

Pre-stroke mm 3.2 3.15 3.25

Beginning of injection position
Governor side NO.1

Difference between angles 1
Cal 1-5 deg. 60 59.5 60.5

Difference between angles 2
Cal 1-3 deg. 120 119.5 120.5

Difference between angles 3
Cal 1-6 deg. 180 179.5 180.5

Difference between angles 4
Cyl.1-2 deg. 240 239.5 240.5

Difference between angles 5
Cal 1-4 deg. 300 299.5 300.5

Injection quantity adjustment

Adjusting point -

Rack position 12

Pump speed r/min 700 700 700

Average injection quantity mm3/st. 88.1 86.5 89.7

Max. variation between cylinders % 0 -2.5 2.5

Basic *

Fixing the rack *

Standard for adjustment of the maximum variation between cylinders *

Injection quantity adjustment_02

Adjusting point H

Rack position 9.5+-0.5

Pump speed r/min 260 260 260

Average injection quantity mm3/st. 9 7 11

Max. variation between cylinders % 0 -14 14

Fixing the rack *

Standard for adjustment of the maximum variation between cylinders *

Injection quantity adjustment_03

Adjusting point A

Rack position R1(12)

Pump speed r/min 700 700 700

Average injection quantity mm3/st. 88.1 87.1 89.1

Basic *

Fixing the lever *

Injection quantity adjustment_04

Adjusting point B

Rack position R1+0.2

Pump speed r/min 1350 1350 1350

Average injection quantity mm3/st. 101.5 98.3 104.7

Fixing the lever *

Injection quantity adjustment_05

Adjusting point C

Rack position (R1-0.15 )

Pump speed r/min 550 550 550

Average injection quantity mm3/st. 80.4 77.2 83.6

Fixing the lever *

Injection quantity adjustment_06

Adjusting point I

Rack position -

Pump speed r/min 100 100 100

Each cylinder's injection qty mm3/st. 107 107 117

Fixing the lever *

Rack limit *

Timer adjustment

Pump speed r/min 850--

Advance angle deg. 0 0 0

Remarks
Start

Timer adjustment_02

Pump speed r/min 800

Advance angle deg. 0.5

Timer adjustment_03

Pump speed r/min 1000

Advance angle deg. 1 0.5 1.5

Timer adjustment_04

Pump speed r/min 1200

Advance angle deg. 2.3 1.8 2.8

Timer adjustment_05

Pump speed r/min 1350

Advance angle deg. 3.5 3 4

Remarks
Finish

Test data Ex:

Governor adjustment

N:Pump speed R:Rack position (mm) (1)Torque cam stamping: T1 (2)Tolerance for racks not indicated: +-0.05mm. (3)RACK LIMIT
----------
T1=D63
----------

Speed control lever angle

F:Full speed I:Idle (1)Stopper bolt set position 'H'
----------

----------
a=18deg+-5deg b=40deg+-3deg

Stop lever angle

N:Pump normal S:Stop the pump.
----------

----------
a=25deg+-5deg b=40deg+-5deg

0000001501 TAMPER PROOF

1. Set the full load. (1)After governor adjustment (torque cam phase adjustment), move the load lever to increase the full rack position to R1. (2)Set using the screw (A) so that the rack position is as shown above and tighten the locknut. (3)Again set in the correct rack position using the load lever.
----------
R1=0.4mm
----------

Timing setting

(1)Pump vertical direction (2)Position of timer's threaded hole at No 1 cylinder's beginning of injection (3)B.T.D.C.: aa (4)-
----------
aa=20deg
----------
a=(40deg)

Information:

This Program must be administered as soon as possible. When reporting the repair, use "PI1324" as the Part Number, "7751" as the Group Number, "56" as the Warranty Claim Description Code and "T" as the SIMS Description Code. Exception: If the repair is done after failure, use "PI1324" as the Part Number, "7751" as the Group Number, "96" as the Warranty Claim Description Code, and "Z" as the SIMS Description Code.
Problem
The 1206437 and 1206438 Couplings used in the 1218021, 1218022, 1218023, and 1218024 Lines Group may slip off of the water piping during operation causing hot engine jacket water to escape from the jacket water circuit.Affected Product
Model & Identification Number
3606 (8RB571, 8RB588, 8RB589, 8RB599, 8RB600, 8RB610, 8RB614-617, 8RB631, 8RB632, 8RB634 , 8RB635)
3608 (6MC489-499, 6MC511, 6MC517, 6MC519, 6MC529)
3612 (9RC167, 9RC168, 9RC185, 9RC187, 9RC190, 9RC192, 9RC199, 9RC201-203, 9RC205, 9RC209-211 , 9RC213, 9RC217, 9RC223)
3616 (1PD184, 1PD198-205, 1PD207-211, 1PD223, 1PD224, 1PD226-231, 1PD237, 1PD238, 1PD245-248 , 1PD250, 1PD254-259, 1PD267, 1PD268)
Parts Needed
4 - 3E7424 Clamp4 - 1242732 Clamp1 - 1378788 Connector1 - 1378789 Connector1 - 1389817 Tube1 - 1389818 TubeAction Required
See attached rework procedure.
Owner Notification
U.S. and Canadian owners will receive the attached Owner Notification.
Service Claim Allowances
Parts Disposition
Handle the parts in accordance with your Warranty Bulletin on warranty parts handling.
MAKE EVERY EFFORT TO COMPLETE THIS PROGRAM AS SOON AS POSSIBLE.
Attach.(1-Owner Notification)(2-Rework Procedure)Copy Of Owner Notification For U.S. And Canadian Owners
Rework Procedure
Procedure: Jacket Water Pump Inlet Connector - Illustration 1
1. Remove the old 1206437 Coupling.2. Measure the gap between the tube ends.If the dimension is within tolerance (104 10 mm) then skip to Step 4. If the tube is not within tolerance, it will need to be removed and either lengthened, or shortened, using the tube provided.3. If lengthening the tube, cut the tube far enough away from the expanded end that the 1389817 Extension will not extend past the taper inside the tube. If shortening the tube, cut and remove a section from the tube of appropriate length, and rejoin the tube by welding the 1389817 Extension between the two halves.4. Install the new 1378788 Coupling. Note that the short end of the coupling goes on the pump side. Tighten the 1242732 Hose Clamps to